Production of cookies having large particulates using ultrasonic wirecutting

ABSTRACT

A method for the continuous production of cookies having a high content of large inclusions, such as chocolate chips, nuts, and fruit pieces includes extruding a cookie dough containing the inclusions through a die orifice to obtain an extrudate dough rope, and cutting the extrudate dough rope with an ultrasonic cutting blade. The ultrasonic cutting severs the extrudate dough rope into dough pieces which fall onto a moving conveyer into a substantially uniform or regular array for uniform baking. The ultrasonic cutter is controlled to provide a roughened top surface on a dough piece to provide a home baked appearance upon baking, while cutting through the inclusions without substantial displacement of the inclusions which would cause pock marks on the surface of the dough piece, and without substantial dough piece weight variation.

FIELD OF THE INVENTION

The present invention generally relates to the continuous production ofcookies having a high content of large inclusions, and moreparticularly, to methods and apparatus for mass producing cookies havinga high content of large inclusions such as chocolate chips, nuts, andfruit pieces, using ultrasonic wirecutting to achieve reduced doughweight variation and a home baked appearance.

BACKGROUND OF THE INVENTION

Traditionally in the mass production of cookies, wirecutting unitoperations may be used to cut dough pieces to the proper weight anddeposit them on an oven band prior to baking unit operations. Achievinguniform dough weights is needed to assure uniform baking, so that doughpieces which are too thin are not overbaked, and dough pieces which aretoo thick are not underbaked. Conventional wire cutting operationsemploy a wire or blade which cuts across a plurality of extruded doughropes to obtain dough pieces which are deposited on a moving belt.Depositing the dough pieces so that they form a regular pattern of rowsacross the belt and along the belt is also needed to assure uniformbaking because dough pieces which are close together bake differentlyfrom those that are far apart.

However, in recent years consumers have requested more indulgent typeproducts which contain large size particulates or inclusions such asraisins, nuts, and confectionary chips or chunks or flavor chips, suchas chocolate chips or chunks. Home-baked chocolate chip cookies aregenerally baked from a dough having the chocolate chips dispersedthroughout the dough. The dough is subdivided into spoon size pieces anddropped onto a baking sheet. A typical recipe provided on the packagingof store-bought chocolate chips calls for about one cup of chocolatechips and about 2.5 cups of other chocolate chip cookie ingredients.This rather large proportion of chocolate chips, the generally largesize of the chocolate chips (bottom diameter of about 0.4 in.) and thedough piece size assure the attainment of cookies having a plurality ofchocolate chips which have a portion which is visually apparent.

Wire-cutting machines are generally used for the mass production ofchocolate chip cookies from a dough, which like a dough prepared athome, contains the chocolate chips dispersed throughout prior to doughpiece formation. On a wire-cutting machine, an extrudate rope is cutinto disc-shaped dough pieces having visually apparent chocolate chips,which may be baked to provide cookies having visually apparent chocolatechips.

Conventional wire-cutting machines, however, cannot be used toconsistently mass produce cookie dough pieces with substantially uniformdough weights having a desirable large amount of large particulates suchas chocolate chips. As the size and amount of particulates or inclusionsare increased, the resistance to cutting increases and there is lessdough through which the resistant pieces may move upon contact with thewire or blade. As a result, the large particulates tend to be draggedacross the cookie dough surface or are partially cut or removed ordisplaced from the dough piece. The dragging and loss of whole orportions of the particulates creates undesirable craters or pock marksin the dough pieces and in the final baked product. In addition, theincreased resistance to cutting, and the displacement or loss ofparticulates causes substantial variation in dough piece weight, andcauses the dough pieces to fall in a more irregular pattern. Forexample, dough piece variation may be 20% by weight or more, and doughpieces may be caused to fall on each other or fall close enough to eachother so that when they are baked and spread in the oven, the piecestouch each other, producing a “double” or a “triple” cookie. Also,particulates or portions thereof may be displaced or dislocated from adough piece, along with adherent dough so that it becomes part ofremains with the dough rope and the subsequently cut dough piece.Uniform baking and packaging suffer as a consequence of the non-uniformdough weights and non-uniform dough piece array.

Furthermore, typical wire cutting operations involve using a wire orblade which would generate buildup of material or breakage of the bladeor wire when attempting to produce doughs with large amounts of largeparticulates, thereby requiring frequent shutdowns to clean or replacethe blades. These problems are further exacerbated when employing stickyor low fat doughs.

While commercially available confectionary or flavor chips or chunks,such as chocolate chips or chunks may have particle sizes of about 500to about 10,000 counts or chips per pound (where the higher the countper pound, the smaller is the size of the chip), commercial wire cuttingoperations are generally limited to flavor chips having a particle sizeof about 3,500 to about 10,000 counts per pound, for example from about4,000 to about 5,000 counts per pound.

Ultrasonic cutting has been employed to provide smooth cutting of foodssuch as baked goods or doughs. Also, ultrasonic molding has beenemployed for precise molding and improved mold release in the productionof foods such as baked goods or doughs.

For example, U.S. Pat. No. 6,431,849 discloses production ofconfectionary products from strips or ropes which may include puffedcereal and candied fruit bits, dry fruits, nuts, or the like. Theproducts are made using an ultrasonic mold to achieve a precise texture,finish or detail.

U.S. Patent publication no. 2005/0196505 discloses ultrasonicallycutting a coextruded dough rope where a specific pattern or ornamentaldesign is produced. The conveyor employed for transporting the cookiedough units, as described in referenced U.S. Pat. Nos. 6,561,235 and6,715,518, raises to support the bottom of the dough rope as the doughrope is cut.

Cutting with an ultrasonic blade, or molding, forming, or imprintingwith an ultrasonic forming tool of foods, such as dough or baked goodsis disclosed in U.S. Patent Publication Nos. 2003/0035876, 2005/0496505,2006/0263504, and 2007/0172559, and U.S. Pat. Nos. 3,817,141, 5,620,713,6,530,768, 6,561,235, 6,627,241, 6,715,518, 7,067,167, and 7,264,836.However, the purpose of the ultrasonic cutting is to provide cleansmooth cuts, so as not to disturb coextruded patterns or areas adjacentto the cut. Providing clean, smooth cuts detracts from the attainment ofa home-baked cookie appearance where surface cracks and varyingtopography are desirably present. Also, the purpose of the ultrasonicforming is to mold or imprint foods into a specific shape while avoidingsticking so as to improve mold release. However, use of a mold providesregular, cookie cutter shapes, and smooth surfaces rather than a homebaked appearance of randomly irregular shapes and random topography.

Cutting through dough ropes having large inclusions such as chocolatechips, nuts and dried fruits, so as to sever the dough rope and providedough pieces which are bakeable to a home-baked, random irregularappearance with surface cracks and highly visible particulates is notdisclosed and would be contrary to achieving a specific coextrudedpattern, or molded or imprinted designs.

In addition, in the processes of the references, the ultrasonic cuttingis performed with the food product being supported on its bottom side,such as ultrasonically cutting of the food when it is on a conveyor.None of the references relate to ultrasonically cutting substantiallyvertically oriented dough ropes and permitting the dough pieces to fallonto a moving conveyor in an array of rows for baking withoutsubstantial deformation of the dough pieces, while achievingsubstantially reduced dough weight variation.

The present invention provides methods and apparatus for the continuous,mass production of cookies having a high content of large inclusions orparticulates, such as chocolate chips, nuts, and fruit pieces, usingultrasonic wirecutting to achieve reduced dough weight variation and ahome baked appearance. The methods of the present invention avoid oreliminate buildup on the cutting blades, distortion of the dough pieces,and excessive deformation of the dough piece surfaces caused by draggingof particulates, as well as breaking of the wire or blade. Additionally,substantial improved control of the dough weights, substantial reductionin waste such as caused by “doubles” and “triples,” and a more uniformlybaked, packageable final product are achieved with the methods of thepresent invention.

SUMMARY OF THE INVENTION

In a first aspect of the invention, cookies having a high content oflarge inclusions are continuously produced by extruding a substantiallyhomogenous cookie dough having a high content of large inclusionsthrough a die aperture above a moving conveyor to provide a verticallyoriented dough rope. In embodiments of the invention, the cookie doughmay have an inclusion content of from about 20% by weight to about 60%by weight, based upon the total weight of the dough, and the inclusionsmay have a particle size of from about 500 count/lb to about 1000count/lb. The vertically oriented dough rope is ultrasonically cut toobtain dough pieces having a roughened top surface while cutting throughinclusions so that the dough pieces fall onto the moving conveyor withthe roughened top surface facing upward.

Dough piece surface roughness may be controlled by varying the powersupply to the ultrasonic cutting blade, or the amplitude of theultrasonic cutting blade. The surface roughness is achieved withoutundesirable distortion of the dough pieces, or excessive deformation ofthe dough piece surfaces caused by dragging of particulates or loss ofthe particulates, which would cause pock marks on the surface of thedough piece. Also, buildup of dough and particulates on the cuttingblade, and breaking of the cutting blade are avoided. In embodiments ofthe invention, the dough weight variation from dough piece to doughpiece may be less than about 10% by weight, based upon the weight of thedough piece.

The dough pieces may be transported on the moving conveyor to an oven,in an at least substantially uniform array and baked into cookies havinga cracked top surface and inclusions which extend above the baked cookiedough top surface. Even though the cookies are mass produced theypossess a home-baked appearance. The method of the present inventionachieves very low dough piece weight variation, and the pieces fall in auniform array on the conveyor which promotes a uniform bakeout,substantially reduces or eliminates the formation of doubles, andreduces waste. The method of the present invention may be employed withfull-fat doughs as well as low fat doughs and sticky doughs.

In another aspect of the invention, a method for reducing dough weightvariation in the continuous production of cookies having a high contentof large inclusions comprises providing a cookie dough with an inclusioncontent of from about 20% by weight to about 60% by weight, based uponthe weight of the total weight of the dough, and an inclusion particlesize of from about 500 count/lb to about 1000 count/lb, and extrudingthe cookie dough through a die orifice to obtain an extrudate rope.Also, the method for reducing the dough weight variation includescutting the extrudate rope with an ultrasonic cutting blade to sever theextrudate rope into dough pieces which fall onto a moving conveyerwithout substantial deformation of the dough pieces, and baking thedough pieces.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is described in the detailed description whichfollows, in reference to the noted plurality of drawings by way ofnon-limiting examples of exemplary embodiments of the present invention.

FIG. 1 schematically shows an ultrasonic wirecutting apparatus which maybe employed for the continuous production of cookies having a highcontent of large inclusions in accordance with the present invention.

FIG. 2 schematically shows a top cross sectional view of the wirecuttingapparatus of FIG. 1 along line 2-2.

FIG. 3 schematically shows a side view of the wirecutting apparatus ofFIG. 2 along line 3-3.

FIG. 4 shows a perspective view of a die insert which may be employedwith the wirecutting apparatus of FIG. 1.

FIG. 5 shows a bottom view of the die insert of FIG. 4.

FIG. 6 shows a right side view of the die insert of FIG. 4.

DETAILED DESCRIPTION OF THE INVENTION

The present invention generally relates to the continuous production ofcookies having a high content of large inclusions, and moreparticularly, to methods for mass producing cookies having a highcontent of large inclusions such as chocolate chips, nuts, and fruitpieces, using ultrasonic wirecutting to achieve reduced dough weightvariation and a home baked appearance.

Generally, inclusions or particulates in a cookie dough provide moreresistance to cutting than does the dough in which they are included. Asthe size and amount of particulates or inclusions in a dough increase,their resistance to cutting and the resistance of the dough compositionto cutting increase. If insufficient energy or power is supplied to theultrasonic cutting blade, the particulates may be substantiallydisplaced, relative to their position in the dough prior to cutting. Thepower level and amplitude of the ultrasonic cutter may generally be highenough to easily cut through doughs and their particulates or inclusionsto provide a clean smooth cut. However, it has been found that if thepower level and amplitude are too high, the cut is generally so smooththat cookies baked from the smooth-surfaced, cut dough pieces exhibit asmooth, shiny appearance which detracts from a creviced, or cracked,varied topography of a home-baked cookie made from a spooned dough.

In embodiments of the invention, the ultrasonic wirecutter is operatedat power levels and amplitudes controlled to cut or sever one or aplurality of vertically oriented dough ropes so that both the dough massand its inclusions or particulates are cut through from end to end. Inaddition, the ultrasonic cutting is controlled so that the inclusions orparticulates are cut through at high enough powers and amplitudes sothat they not substantially pushed or displaced through the dough to anextent that they are removed or leave a pock mark, crater, or trail inthe dough surface. Moreover, the ultrasonic cutting is also controlledso that the power level and amplitude of the cutting provide a roughenedsurface to the severed dough piece. The roughened dough surface helps toachieve a non-smooth, non-glossy or non-shiny appearance and randomsurface cracks or crevices and a random varied topography as in homebaked, spooned cookies. Generally, in embodiments of the invention, theroughened dough surface may have a topography similar to that of coarsesandpaper so as to avoid a glassy appearance.

In addition, the ultrasonic cutting employed in the present inventiondoes not substantially displace the severed piece from a downwardly orvertically directed path. The severed pieces fall flat on a movingconveyor, and not on edge or on each other. They fall with a roughenedtop surface in a regular pattern of straight rows for uniform baking.Moreover, the dough pieces are cut in substantially equal weights, withdough piece weight variation in embodiments of the invention of lessthan about 10% by weight being achieved.

In embodiments of the invention, the power supply to the ultrasoniccutting blade, and the amplitude of the ultrasonic cutting blade may becontrolled and varied to produce surface roughness on the dough pieces.The ultrasonic cutter may vibrate at a frequency of about 20,000kilohertz or 20,000 cycles per second, or more, for example up to about30,000 kilohertz to about 40,000 kilohertz. Generally, the whole bladeexpands and contracts, like a rubber band, from the energy input, andthe range of that motion, or amplitude, may be 20 microns, and with a1.5 booster gain may be 30 microns. At high power inputs and highamplitudes, friction is reduced and the dough is cut with lessresistance and a smooth, glassy cut is obtained. In accordance withembodiments of the present invention, the amplitude is reduced so thatthe blade does not expand and contract as much, the velocity is reduced,and a rougher cut or rougher surface is achieved at a given frequency.The amplitude may be changed, or reduced in accordance with the presentinvention by lowering the booster unit output level and with electroniccontrols on the power supply. The amplitude may be changed mechanicallyand may also be fine tuned, e.g. in 1% increments from 100% to 20%, withelectronic controls by a skilled operator in known manner. The powersupply may be analogue or digital, and may be adjusted by a skilledoperator in known manner.

In accordance with preferred embodiments of the present invention, toachieve reduction in amplitude which provides a desirable surfaceroughness, the power booster may be reduced or set at from about 35% toabout 65%, more preferably from about 40% to about 60%, of its maximumcapacity (100% setting). For example, for a blade amplitude of 20microns peak to peak, and a booster gain of 1.5, reducing the booster to60% may result in an amplitude of about 18 microns of motion (20microns×0.6×1.5×18 microns). In exemplary embodiments of the invention,for a booster gain of 1.5, the amplitude of blade motion may be 10microns to 19 microns, preferably from 12 microns to 18 microns.

In addition, to produce dough piece surface roughness, in embodiments ofthe invention, the power supply to the ultrasonic cutting blade, and theamplitude of the ultrasonic cutting blade may be controlled at a fixedreduced level, or may be varied as the cutter travels or cuts across thedough rope to produce the dough pieces.

Commercially available ultrasonic cutter components and blades may beemployed in the present invention. Exemplary ultrasonic cuttingequipment which may be used is manufactured by Dukane Corporation, St.Charles Ill. The ultrasonic components which may be used include: a) anultrasonic generator/power supply which converts line voltage into a 20,30, or 40 kHz signal that is sent to an ultrasonic converter, b) asealed ultrasonic converter which converts the generator signal intomechanical motion through the use of piezoelectric crystals(approximately 20μ of amplitude peak to peak, c) a booster which is usedto maintain, decrease or increase the amplitude of the cuttingblade/horn, and also acts as a mounting point for integration, and d) anultrasonic cutting blade which is connected to the booster, which aregenerally used for guillotining or slitting products. Exemplaryultrasonic cutting blades are half wave guillotine, half wave edgeguillotine, full wave guillotine, and full wave wedge guillotine cuttingblades. Preferred ultrasonic cutting blades for use in the presentinvention are a half wave guillotine cutting blade, and a half wavewedge guillotine cutting blade which come in standard lengths rangingfrom 6 inches to 14 inches, manufactured by Dukane Corporation.

The ultrasonic cutter may be mounted on a conventional wirecuttingmachine, such as a wirecutter manufactured by APV Baker, Baker PerkinsGroup Ltd. Each wirecutting machine may be fitted with one or more thanone ultrasonic cutting blade, with each blade having its own ultrasoniccomponents including an ultrasonic power supply, converter, and booster,so that the amplitude of each blade may be adjusted independently. Inembodiments of the invention, oven bands may be 36 inches wide or more,which would be too wide for a single ultrasonic blade to effectivelyspan, because amplitude may diminish too much as the distance along theblade increases from the location of the blade mounting section. Wheremultiple blades and ultrasonic cutting components are employed on asingle wirecutting device, the ultrasonic cutting devices and theirblades may be journaled or connected together or mounted or attached toa single reciprocating mechanism to synchronize their movement forcutting a plurality of at least substantially vertically orientedextrudate dough ropes. The synchronization of the movement of the bladesis such so that all of the blades contact and cut one or a plurality ofdifferent extrudate ropes at least substantially simultaneously so thatthe cut dough pieces fall in an at least substantially uniform straightrow across the oven band. For example, for a 36 inch wide band, threeultrasonic cutting blades and their three ultrasonic cutting units maybe employed to simultaneously cut a plurality of dough ropes which areextruded from a plurality of wirecutter dies arranged across thewirecutter and across the conveyer band. Generally, each blade employedin embodiments of the invention may have a length of about 12 inches,and 3 or 4 blades may be employed across an oven band.

The mounting of the ultrasonic cutter on the wirecutter may be so thatthe cutting of the dough rope preferably occurs in the same directionthat the underlying conveyor belt and cut dough pieces thereon aremoving. However, in embodiments of the invention, the ultrasonic cuttermay be mounted 180°, so that the cutting of the dough rope occurs in thedirection opposite to the movement of the underlying conveyor belt andcut dough pieces which have fallen upon the conveyor.

The reciprocating mechanism of the wirecutter, may move the ultrasoniccutting blade and its components so that the ultrasonic cutting bladetravels in a looped path to cut the dough rope at the wirecutter dieaperture. In preferred embodiments, the ultrasonic cutting blade maytravel in a curved or elliptical path or gradual arc, so that the bladecuts across the dough rope first in an upward direction as the leadingedge of the blade first encounters the dough rope, and then in adownward direction as the leading edge of the blade leaves the doughrope. The upward cutting, towards the die aperture may reverse to thedownward cutting away from the die aperture, at about 60% to about 90%across the maximum width, thickness, or diameter of the dough rope ordie aperture. The downward motion helps to cleanly separate the doughpiece from the remaining portion of the extrudate rope so that thesevered dough does not tend to momentarily stick or reattach to thedough rope from which it is being severed and hinder and adverselyaffect its vertical or straight down fall into a straight row and array.

In preferred embodiments, the dough rope is cut by the ultrasonic bladeas close as possible to the die orifice without contacting the die. Thiscutting of the dough rope at the die aperture helps to reduce movementof the dough rope in the direction of travel of the blade because theinternal walls of the die passageway support the rope against lateralmovement. As the distance away from the die orifice increases, thevertically oriented dough rope has more flexibility and swaying room,and less support from the internal walls of the die passageway.Accordingly as the cutting distance from the die orifice increases, thedough pieces tend to fall in a more irregular pattern. In preferredembodiments, upon cutting the dough rope the top edge of the blade maybe at a distance of less than about 20/1000 inches, preferably less thanor equal to about 10/1000 inches from the die aperture.

The distance between the wirecutter die aperture or orifice and theunderlying conveyor belt should be large enough to permit the ultrasoniccutting blade to move in its reciprocating looped path. However, shorterdistances are preferred to reduce the possibility of the dough piecesturning or flipping as they fall, or falling out of alignment with eachother on the conveyor belt. In embodiments of the invention, thedistance the pieces may be permitted to fall from the die aperture orexit to the underlying conveyor belt or band may be from about 1.5inches to about 12 inches, for example from about 2 inches to about 6inches, preferably about 2 inches.

Generally, commercially available wire cutters contain a circular dieorifice or aperture, which results in dough pieces and cookies whichhave regular, circular shapes or peripheries which provide a cookiecutter type or mass produced appearance, rather than a spooned,home-baked irregular circumference. While the wirecutter die aperturesor orifices employed in the present invention may have any shape, suchas circular, or other regular shapes, or designs, in preferredembodiments, to obtain a more home-baked, spooned cookie appearance thedie orifice employed in the present invention may have an irregularshape. The irregularly shaped die aperture or orifice may provide doughpieces having a curvilinear perimeter so that upon baking the doughpieces are baked into cookies having a curvilinear periphery.

In embodiments of the invention a die insert may be employed to providean irregular circumference to the dough rope and the cookies baked fromthe severed dough pieces. The curvilinear die aperture, and curvilinearperimeter of the dough rope and cookies produced therefrom may be madeup of a plurality of alternating concave, convex, and linear portions orsections of varying length. The concave and convex curved portions mayhave different radii of curvature or differently shaped arcs to providea random, spooned cookie shape, periphery, or circumference. Inembodiments of the invention, the number of differently shaped portionsor sections of the die orifice, and dough pieces and cookies producedtherewith may be at least about 10, preferably at least about 15, forexample from about 18 to about 23.

The die insert may have a circular input end which fits into thecircular die of the wirecutter, and an opposing output end whichcontains the irregularly shaped curvilinear die aperture. A flange maybe provided for securing or attaching the die insert to the wirecutterwith bolts or other fastening devices which pass through holes in theflange. In preferred embodiments, the die insert may have an innerpassageway which tapers inwardly or narrows from the circular input endto the irregular output end. The tapered passageway helps to compressthe dough and conform it to the irregular shape of the die exit orifice.In embodiments of the invention the amount of taper may be less thanabout 10°, preferably less than about 5°, for example from about 2° toabout 4° from the longitudinal axis of the passageway of the die or dieinsert.

In embodiments of the invention a linear air nozzle or “air knife” maybe employed to provide air to the ultrasonic cutting blade surfaces tokeep them clean. During prolonged cutting, small fines from cutting ofthe dough and the inclusions tend to build up on the blade surfaceswhich may adversely affect cutting efficiency. If the fines sit on theblade surface too long, they may begin to melt or cook due the heatgenerated on the blade from the ultrasonic vibration. The air knife mayapply a gentle curtain of air to the top of the ultrasonic blade surfaceas the blade changes its direction from retraction to forward in thecutting cycle or loop. Application of the air curtain to the blade maybe synchronized with the position of the blade in its travel path usingknown synchronization techniques.

An air knife may be provided for each ultrasonic blade and may bemounted on the wirecutter, underneath and upstream of the dies in afixed position over each of the ultrasonic blades. In embodiments of theinvention the air pressure employed with the air knife may be from about5 psig to about 20 psig, for example about 10 psig to about 15 psig.Linear air nozzles or air knives which may be employed in the presentinvention are commercially available, such as a Linear Air and Blow-OffNozzle, made by Exair Corporation of Cincinnati, Ohio.

FIG. 1 schematically illustrates an ultrasonic wirecutting apparatus 1which may be employed for the continuous production of cookies having ahigh content of large inclusions in accordance with the presentinvention. As illustrated in FIG. 1, the wirecutting apparatus 1 cancomprise a hopper 5 provided with a pair of counter-rotating feedrollers 10 positioned at a lower portion thereof for feeding cookiedough 15 from the hopper through a die plate 20. The direction ofrotation of the counter-rotating feed rollers 10 is indicated by arrows.Positioned below the counter-rotating feed rollers 10 can be provided awire cutter die or die plate 20 having one or more die orifices 25 witha die insert 30 inserted in each die orifice for extruding one or moreropes 35. In an alternative arrangement of the wirecutting apparatus 1,the counter-rotating feed rollers 10 may be replaced with another typeof feeding mechanism for feeding and forcing the cookie dough throughthe die inserts 30. For example, the counter-rotating feed rollers canbe replaced with a spiral screw conveyor.

The die orifices 25 and die inserts 30 can be located beneath thecounter-rotating feed rollers 10, and an ultrasonic cutting blade 50 canbe positioned below the die insert 30. The cookie dough 15 is formedinto ropes 35 by the wire cutter die insert 30, which are then cut intoindividual pieces 55 by the ultrasonic cutting knife or blade 50. Theindividual pieces 55 can be substantially uniformly received by conveyor60 and transferred to an oven 70 and packager (not shown).

As shown in FIGS. 1, 2, and 3, the ultrasonic cutting blade 50 may beattached to the horn 75 of an ultrasonic cutter assembly 80, which mayinclude a booster 85, and a transducer 90. The ultrasonic cutterassembly 80 may be mounted at the underside or bottom 95 of thewirecutter 1 to the reciprocating mechanism 100 of the wirecutter 1 formoving the ultrasonic cutting blade 50 in a looped path. A knifemounting assembly 105 may be used to attach, connect, or mount theultrasonic cutter assembly 80 to the wirecutter reciprocating mechanism100 with conventional fastening devices such as bolts and nuts, screws,and conventional fittings.

As schematically shown in FIGS. 2 and 3, two or more ultrasonic cutterassemblies 80 may be mounted on the knife mounting assembly 105 with theleading edges 110 of the ultrasonic knives or blades aligned forsimultaneous travel across the die orifices 25 and die inserts 30 forsimultaneous cutting of a plurality of dough ropes 50. As shown in FIG.1 and FIG. 2, the dough ropes 50 are cut into a plurality of doughpieces 55 using a reciprocating motion of the ultrasonic blade 50, andthe dough pieces 55 fall onto conveyor 60 in a substantially uniformarray of substantially uniformly spaced rows across the width of theconveyor belt 60 and along the length of the conveyor belt 60.

Additionally, as shown schematically in FIG. 2 and FIG. 3, an air knife115 may be mounted to the wirecutting apparatus for blowing a curtain ofair 120 onto the ultrasonic blade 50 to remove fines from the blade 50when it is retracted to begin its cyclical travel in a looped path.

As shown in detail in FIGS. 4-6, the die insert 30 may have acurvilinear die aperture 130 which contains a plurality of alternatingconcave portions or sections 135, convex portions or sections 140, andlinear portions or sections 145 of varying length. The concave curvedportions 135 and the convex curved portions 140 may each have differentradii of curvature or differently shaped arcs to provide a random,spooned cookie shape, periphery, or circumference.

The die insert 30 may have a circular input end 150 which fits into thecircular die orifice 25 of the wirecutter 1, and an opposing output end155 which contains the irregularly shaped curvilinear die aperture 130.A flange 160 may be provided near the input end 150 for securing orattaching the die insert 30 to the wirecutter 1 with bolts or otherfastening devices which pass through holes 165 in the flange 160. Inpreferred embodiments, the die insert 30 may have an inner passageway170 which tapers inwardly or narrows from the circular input end 150 tothe irregular output end 155. The inner passageway 170 may have thecurvilinear shape of the die aperture 130 which may extend from theoutput end 155 to or near the input end 150.

Any type of edible inclusion, particulate, or particulate flavoringingredient, or morsel in any shape or form, such as chips or chunks, maybe used in the present invention. The chips or chunks may beconfectionary chips, confectionary chunks, flavor chips, flavor chunks,flavor chips, flavor chunks, compound chips or compound chunks, and theterms are used interchangeably herein. A chip or chunk may be achocolate chip or chocolate chunk, or a flavor compound or confectionarycompound such as a butter flavor chip or chunk. A confectionary chip orchunk may be a compound chip that might be chocolate flavored, but isnot limited to chocolate flavored. Exemplary inclusions, particulates orparticulate flavoring ingredients, or morsels which may be employed inthe present invention include white, dark, or milk chocolate chips orchunks, butterscotch chips or chunks, vanilla chips or chunks, butterchips or chunks, peanut butter chips or chunks, coconut chips or chunks,caramel chips or chunks, fruit flavored chips or chunks, or otherflavored chips or chunks, raisins, dried or dehydrated cranberries,raspberries, blueberries, strawberries, or other dried berries, fruitpieces, such as dried or dehydrated fruit pieces including apricot,apple, plum, peach, orange, banana, pineapple, mango, currant, sultana,and cherry pieces, nuts, or pieces of nuts such as macadamia nuts,peanuts, walnuts, almonds, hazelnuts, pecans, brazil nuts, pistachios,seeds such as pumpkin seeds, roasted or non-roasted coffee beans, driedor dehydrated vegetable pieces, such as carrot pieces, broccoli pieces,sun dried tomatoes, candy or candy bar pieces, ready-to-eat cerealclusters, and mixtures thereof. Exemplary shapes or forms of theinclusions which may be employed include drop shaped, chunk shaped,slices, diced, chopped or whole, such as whole raisins, whole macadamianuts, whole peanuts, and mixtures thereof.

In embodiments of the invention, the cookie dough inclusion content maybe from about 20% by weight to about 60% by weight, for example fromabout 25% by weight to about 50% by weight, based upon the total weightof the dough (which includes the weight of the inclusions and the weightof all other dough ingredients). In embodiments of the present inventionany inclusion particle size, such as from about 300 count/pound to about10,000 count/pound may be employed. In preferred embodiments, aninclusion or particulate particle size of from about 500 count/lb toabout 1000 count/lb is employed for desirable visual impact, andtextural dichotomy. The length, width, height, and diameter of theinclusions for a given count/pound, may vary depending upon the type ofinclusion, and its density. Generally, the inclusions employed with acount/pound of from about 500 to about 1000 may have at least onedimension, such as length, which on average is at least about 0.4inches. For example, cranberries which may be employed may have anaverage length of about 0.702 inches, an average width of about 0.479inches, and an average height of about 0.202 inches. Chocolate chunkswith a particle size of about 600 count/pound may have an average lengthof about 0.478 inches, an average width of about 0.367 inches, and anaverage height of about 0.268 inches. Smaller size range chocolatedrops, such as used in conventional wirecutting operations may have aparticle size of about 4200 count/pound with an average diameter ofabout 0.230 inches, and an average height of about 0.228 inches.

In embodiments of the invention, mixtures of inclusions having differentparticle size ranges may be employed. For example, a mixture ofinclusions employable in the present invention may have from about 25%by weight to about 35% by weight large particulates having a particlesize of from about 500 count/pound to about 1000 count per pound, andfrom about 15% by weight to about 25% by weight of smaller particulateshaving a smaller particle size of from about 4000 count/pound to about5000 count/pound, based upon the total weight of the dough, for a totalparticulate load or content of from about 40% by weight to about 60%,based upon the total weight of the dough.

In preferred embodiments of the invention, the particulates aresufficiently large and in sufficiently plentiful amounts so that afterbaking of the cookie dough, the inclusions extend above the baked cookiedough top surface, as a result of oven spread. Upon baking, the cookiedough spreads to a considerable degree compared to the spread, if any,of the inclusion, such as nuts, raisins, or confectionary or flavorchips or chunks. Accordingly, inclusions contained within the dough maypierce through the dough surface upon baking, and may extendsubstantially above the cookie surface, to provide a rich, indulgentappearance. For example, in embodiments of the invention, at least about15%, preferably at least about 25%, most preferably at least about 50%of a dimension, such as height, of a plurality of inclusions may beabove the baked dough surface of the cookie. The inclusions, such asconfectionary chips or chunks or flavor chips or chunks, and nuts mayhave a maximum dimension which is greater than the thickness to whichthe cookie dough spreads to assure piercing of the chips through the topsurface of the cookie dough.

As used herein, the term “cookie” is intended to include any bakedproduct being similar to a cookie such as cookies, biscuits, and thelike. Similarly, the term “cookie dough” is intended to mean any doughthat can be used to make cookies within the broadest meaning of thatterm. Such a dough is usually an unbaked mixture of ingredients used tomake a cookie dough such as flour, shortening (such as for examplemargarine or butter), fat, one or more than one sugar, such as sucrose,and water. In addition, the dough may contain a leavening agent, e.g.baking powder containing sodium bicarbonate or ammonium bicarbonate.

In embodiments of the invention, the flour component or farinaceousmaterials employed may be any comminuted cereal grain or edible seed orvegetable meal, derivatives thereof and mixtures thereof. Exemplary ofthe flour component or farinaceous materials which may be used are wheatflour, corn flour, corn masa flour, oat flour, barley flour, rye flour,rice flour, potato flour, grain sorghum flour, tapioca flour, grahamflour, or starches, such as corn starch, wheat starch, rice starch,potato starch, tapioca starch, physically and/or chemically modifiedflours or starches, such as pregelatinized starches, and mixturesthereof. The flour may be bleached or unbleached. Wheat flour ormixtures of wheat flour with other grain flours are preferred.

The flour component may be replaced in whole or in part by resistantstarch ingredients, such as resistant starch type III ingredients, orresistant starch bulking agents, resistant starch flour substitutes, orother flour substitutes or bulking agents, such as polydextrose,hollocellulose, microcrystalline cellulose, mixtures thereof, and thelike. Corn bran, wheat bran, oat bran, rice bran, mixtures thereof, andthe like may also be substituted in whole or in part for the flourcomponent to enhance color, or to affect texture. The amount of thebulking agent, or flour substitute or resistant starch ingredient such aresistant starch type III ingredient, may generally be at least about25% by weight, for example at least about 40% by weight, preferably fromabout 50% by weight to about 75% by weight, based upon the total weightof the bulking agent or flour substitute and the flour component, suchas conventional, ungelatinized wheat flour.

In embodiments of the invention, the total amount of the flour componentand the optional bulking agent, flour substitute, or resistant starchingredient, such as resistant starch type bulking agent which may beused in the compositions of the present invention may range, forexample, from about 20% by weight to about 80% by weight, preferablyfrom about 45% by weight to about 75% by weight, based upon the weightof the dough, not including the weight of inclusions. Unless otherwiseindicated, all weight percentages are based upon the total weight of allingredients forming the doughs or formulations of the present invention,except for inclusions such as confectionary or flavor chips or chunks,nuts, raisins, and the like. Thus, “the weight of the dough” does notinclude the weight of inclusions, but “the total weight of the dough”does include the weight of inclusions.

Process-compatible ingredients, which can be used to modify the textureof the products produced in the present invention, include sugars suchas sucrose, fructose, lactose, dextrose, galactose, maltodextrins, cornsyrup solids, hydrogenated starch hydrolysates, protein hydrolysates,glucose syrup, mixtures thereof, and the like. Reducing sugars, such asfructose, maltose, lactose, and dextrose, or mixtures of reducing sugarsmay be used to promote browning. Fructose is the preferred reducingsugar, because of its ready availability and its generally more enhancedbrowning and flavor-development effects. Exemplary sources of fructoseinclude invert syrup, high fructose corn syrup, molasses, brown sugar,maple syrup, mixtures thereof, and the like.

The texturizing ingredient, such as sugar, may be admixed with the otheringredients in either solid or crystalline form, such as crystalline orgranulated sucrose, granulated brown sugar, or crystalline fructose, orin liquid form, such as sucrose syrup or high fructose corn syrup. Inembodiments of the invention, humectant sugars, such as high fructosecorn syrup, maltose, sorbose, galactose, corn syrup, glucose syrup,invert syrup, honey, molasses, fructose, lactose, dextrose, and mixturesthereof, may be used to promote chewiness in the baked product.

In addition to the humectant sugars, other humectants, or aqueoussolutions of humectants which are not sugars or possess a low degree ofsweetness relative to sucrose, may also be employed in the dough orbatter. For example, glycerol, sugar alcohols such as mannitol,maltitol, xylitol and sorbitol, and other polyols, may be used ashumectants. Additional examples of humectant polyols (i.e. polyhydricalcohols) include glycols, for example propylene glycol, andhydrogenated glucose syrups. Other humectants include sugar esters,dextrins, hydrogenated starch hydrolysates, and other starch hydrolysisproducts.

In embodiments of the present invention, the total sugar solids content,or the texturizing ingredient content, of the doughs of the presentinvention may range from zero up to about 50% by weight, based upon theweight of the dough, not including the weight of inclusions.

The sugar solids may be replaced in whole or in part by a conventionalsugar substitute or conventional bulking agent such as polydextrose,hollocellulose, microcrystalline cellulose, mixtures thereof, and thelike. Polydextrose is a preferred sugar substitute or bulking agent formaking reduced calorie baked goods. Exemplary replacement amounts may beat least about 25% by weight, for example at least about 40% by weight,preferably from about 50% by weight to about 75% by weight, of theoriginal sugar solids content.

In embodiments of the invention, the amount of the conventional sugarsubstitute, conventional bulking agent, or conventional floursubstitute, such as polydextrose, may be from about 10% by weight toabout 35% by weight, for example from about 15% by weight to about 25%by weight, based upon the weight of the dough, not including the weightof the inclusions.

The moisture contents of the doughs of the present invention should besufficient to provide the desired consistency to enable proper forming,machining, and cutting of the dough. The total moisture content of thedoughs of the present invention will include any water included as aseparately added ingredient, as well as the moisture provided by flour(which usually contains about 12% to about 14% by weight moisture), themoisture content of any bulking agent or flour substitute such as aresistant starch type III ingredient, and the moisture content of otherdough additives included in the formulation, such as high fructose cornsyrup, invert syrups, or other liquid humectants.

Taking into account all sources of moisture in the dough or batter,including separately added water, the total moisture content of thedoughs or batters which may be used in the present invention isgenerally less than about 50% by weight, preferably less than about 35%by weight, based upon the weight of the dough or batter, not includingthe weight of the inclusions. For example, cookie doughs employed in thepresent invention may have a moisture content of less than about 30% byweight, generally from about 10% by weight to about 20% by weight, basedupon the weight of the dough, not including the weight of inclusions.

Oleaginous compositions which may be used to obtain the doughs and bakedgoods of the present invention may include any known shortening or fatblends or compositions, useful for baking applications, such as butter,and they may include conventional food-grade emulsifiers. Vegetableoils, lard, marine oils, and mixtures thereof, which are fractionated,partially hydrogenated, and/or interesterified, are exemplary of theshortenings or fats which may be used in the present invention. Ediblereduced- or low-calorie, partially digestible or non-digestible fats,fat-substitutes, or synthetic fats, such as sucrose polyesters ortriacyl glycerides, which are process-compatible may also be used.Mixtures of hard and soft fats or shortenings and oils may be used toachieve a desired consistency or melting profile in the oleaginouscomposition. Exemplary of the edible triglycerides which can be used toobtain the oleaginous compositions for use in the present inventioninclude naturally occurring triglycerides derived from vegetable sourcessuch as soybean oil, palm kernel oil, palm oil, rapeseed oil, saffloweroil, sesame oil, sunflower seed oil, and mixtures thereof. Marine andanimal oils such as sardine oil, menhaden oil, babassu oil, lard, andtallow may also be used. Synthetic triglycerides, as well as naturaltriglycerides of fatty acids, may also be used to obtain the oleaginouscomposition. The fatty acids may have a chain length of from 8 to 24carbon atoms. Solid or semi-solid shortenings or fats at roomtemperatures of, for example, from about 75° F. to about 95° F. may beused. Preferred oleaginous compositions for use in the present inventioncomprise soybean oil.

Baked goods which may be produced in accordance with the presentinvention include reduced calorie baked goods which are also reducedfat, low fat or no-fat products. As used herein, a reduced-fat foodproduct is a product having its fat content reduced by at least 25% byweight from the standard or conventional product. A low-fat product hasa fat content of less than or equal to three grams of fat per referenceamount or label serving. However, for small reference amounts (that is,reference amounts of 30 grams or less or two tablespoons or less), alow-fat product has a fat content of less than or equal to 3 grams per50 grams of product. A no-fat or zero-fat product has a fat content ofless than 0.5 grams of fat per reference amount and per label serving.For accompaniment crackers, such as a saltine cracker, the referenceamount is 15 grams. For crackers used as snacks and for cookies, thereference amount is 30 grams. Thus, the fat content of a low-fat crackeror cookie would therefore be less than or equal to 3 grams of fat per 50grams or less than or equal to about 6% fat, based upon the total weightof the final product. A no-fat accompaniment cracker would have a fatcontent of less than 0.5 grams per 15 grams or less than about 3.33%,based upon the weight of the final product.

In addition to the foregoing, the doughs of the invention may includeother additives conventionally employed in crackers and cookies. Suchadditives may include, for example, milk by-products, egg or eggby-products, cocoa, vanilla or other flavorings, in conventionalamounts.

A source of protein, which is suitable for inclusion in baked goods, maybe included in the doughs employed in the present invention to promoteMaillard browning. The source of protein may include non-fat dry milksolids, dried or powdered eggs, mixtures thereof, and the like. Theamount of the proteinaceous source may, for example, range up to about5% by weight, based upon the weight of the dough, not including theweight of inclusions.

The dough compositions of the present invention may contain up to about5% by weight of a leavening system, based upon the weight of the dough,not including inclusions. Exemplary of chemical leavening agents orpH-adjusting agents which may be used include alkaline materials andacidic materials such as sodium bicarbonate, ammonium bicarbonate,calcium acid phosphate, sodium acid pyrophosphate, diammonium phosphate,tartaric acid, mixtures thereof, and the like. Yeast may be used aloneor in combination with chemical leavening agents.

The doughs employed in the present invention may include antimycotics orpreservatives, such as calcium propionate, potassium sorbate, sorbicacid, and the like. Exemplary amounts, to assure microbialshelf-stability, may range up to about 1% by weight of the dough, notincluding the weight of inclusions.

Emulsifiers may be included in effective, emulsifying amounts in thedoughs of the present invention. Exemplary emulsifiers which may be usedinclude, mono- and di-glycerides, polyoxyethylene sorbitan fatty acidesters, lecithin, stearoyl lactylates, and mixtures thereof. Exemplaryof the polyoxyethylene sorbitan fatty acid esters which may be used arewater-soluble polysorbates such as polyoxyethylene (20) sorbitanmonostearate (polysorbate 60), polyoxyethylene (20) sorbitan monooleate(polysorbate 80), and mixtures thereof. Examples of natural lecithinswhich may be used include those derived from plants such as soybean,rapeseed, sunflower, or corn, and those derived from animal sources suchas egg yolk. Soybean-oil-derived lecithins are preferred. Exemplary ofthe stearoyl lactylates are alkali and alkaline-earth stearoyllactylates such as sodium stearoyl lactylate, calcium stearoyllactylate, and mixtures thereof. Exemplary amounts of the emulsifierwhich may be used range up to about 3% by weight of the dough, notincluding the weight of inclusions.

Production of the doughs of the present invention may be performed usingconventional dough mixing techniques and equipment used in theproduction of cookie and cracker doughs.

While baking times and temperatures will vary for different dough orbatter formulations, oven types, etc., in general, commercial cookie,brownie and cake-baking times may range from about 2.5 minutes to about15 minutes, and baking temperatures may range from about 250° F. (121°C.) to about 600° F. (315° C.).

The baked products of the present invention may have a relative vaporpressure (“water activity”) of less than about 0.7, preferably less thanabout 0.6, for preservative free microbial shelf-stability. Cookie,brownie and cake products generally have a moisture content of less thanabout 20% by weight, for example, from about 2% by weight to about 9% byweight for cookies, based upon the weight of the baked product,exclusive of inclusions.

The cookie dough or batter compositions employed in the presentinvention may be used for the production of reduced calorie, reducedfat, low fat, no-fat, or full fat cookies such as drop-type cookies suchas chocolate chip cookies, oatmeal cookies, sugar cookies, chocolatecookies, vanilla cookies, gingerbread cookies, peanut butter cookies,butterscotch cookies, short bread cookies, fruit cookies, and the like,containing high amounts of large particulates. The cookies may be madein a variety of sizes, for example cookies having a maximum diameter offrom about 1.5 inches to about 4 inches, preferably about 2 inches toabout 3.5 inches, most preferably from about 2.75 inches to about 3.25inches.

The present invention is further illustrated in the following examples,where all parts, ratios, and percentages are by weight, and alltemperatures are in ° F., unless otherwise stated:

EXAMPLE 1

The ingredients and their relative amounts, which may be used to producean oatmeal cookie having high amounts of 600 to 1000 count/poundcranberry and macadamia nut inclusions and a home-baked appearance inaccordance with the present invention are:

PARTS BY DOUGH INGREDIENT WEIGHT WEIGHT % GROUP 1 Butter 80.00 16.54Fine Grain Sugar, sucrose 55.25 11.42 Light Brown Sugar 55.25 11.42 Salt2.00 0.41 Liquid Fructose 25.38 5.24 Flavoring 2.88 0.60 GROUP 2 SprayDried Eggs 3.00 0.62 Water 8.25 1.71 Vanilla 2.00 0.41 GROUP 3 RolledOats 20.00 4.14 Wheat Flour 100.00 20.68 Sodium Bicarbonate 2.14 0.44Ammonium Bicarbonate 0.50 0.10 Water 2.00 0.41 GROUP 4 Cranberries 75.0015.52 Macadamia Nuts, diced 50.00 10.34 TOTAL 483.65 100.0

The cranberries may have an average length of about 0.7 inches, anaverage width of about 0.5 inches, and an average height of about 0.2inches. The Macadamia nuts may have an average length of about 0.4inches, an average width of about 0.35 inches, and an average height ofabout 0.3 inches.

The dough may be produced by first blending the Group 1 ingredients forabout three minutes at high speed. The Group 2 ingredients may then beadded to the Group 1 ingredients with mixing for about two minutes atlow speed, followed by addition of the Group 3 ingredients with mixingfor an additional two minutes at low speed. The Group 4 ingredients maythen be added and mixing may be continued for three minutes at low speedto obtain a substantially homogeneous dough.

The dough may be placed onto a lay-time conveyor for about 30 minutesfor hydration purposes. The dough may then be transferred to the hopperof a wirecut apparatus as shown in FIGS. 1-6. The wirecut apparatus maybe a conventional wirecutter manufactured by APV Baker, Baker PerkinsGroup Ltd., which is modified to include two ultrasonic cutterscontaining ultrasonic cutter components and blades manufactured byDukane Corporation, St. Charles Ill. The Dukane Corporation ultrasoniccomponents for each ultrasonic cutter may include an ultrasonicgenerator/power supply, an ultrasonic converter, which converts thegenerator signal into mechanical motion through the use of piezoelectriccrystals (approximately 20μ of amplitude peak to peak), a booster, ahorn, and an ultrasonic cutting blade which is connected to the boosterthrough the horn. Each ultrasonic cutting blade may be a half wave wedgeguillotine blade which is 6 inches in length.

Each ultrasonic blade may be set so that the distance between the topsurface of the blade and the bottom of the die insert is 10/1000 of aninch. The booster may be set to about 40% (0.4:1 ratio booster) toreduce the blade amplitude by about 60%. A linear air nozzle or airknife made by Exair Corporation of Cincinnati, Ohio may be employed toremove fines from the top of the blade.

The cookie dough may be extruded through four dies, as shown in FIGS.1-3 each having an inner diameter or orifice of about 2 inches to obtainfour extrudate dough ropes. Each die may be fitted with an irregular dieinsert having an aperture or exit orifice inner diameter of about 2inches, as shown in detail in FIGS. 4-6. The four extrudate dough ropesmay be cut simultaneously using the two ultrasonic cutters to obtaindough pieces which fall about two inches from the exit of the die insertto the underlying conveyor belt in a substantially regular array asshown in FIGS. 1-3. The conveyor belt may be a 16 inch wide oven band.The dough pieces may have a curvilinear circumference or perimeter asprovided by the die insert.

The wirecutter may be set to attain a target dough piece weight of 30grams per piece. A plurality of dough pieces may be taken from thearray, and weighed to determine the dough weight variation. The doughweights for a sample size of about 14 dough pieces may range from about27 grams to about 33 grams, for a dough weight variation of 10% from thetarget dough weight (33−30=3 and 30−27=3, so the dough weight variationis 3/30×100=10%). The dough may be wirecut using a conventionalwirecutter and wire blade with no ultrasonic cutting. The dough weightsfor the same sample size may range from about 24 grams to about 36grams, for a dough weight variation of about 20% from the 30 gram targetweight ( 6/30×100=20%). Thus, use of the ultrasonic cutter in accordancewith the present invention reduces the dough weight variation by about50% ( 10/20=50%).

The dough pieces on the oven band may be transported to a band ovenhaving five zones for baking into cookies. The dough pieces may be bakedat top zone temperatures ranging from about 250° F. to about 400° F.,and bottom zone temperatures of about 200° F. to about 325° F. and thebaking time may be about 10 minutes. The cookies may have a moisturecontent of about 5.5% by weight and a maximum diameter of about 3inches.

The cookies may have a curvilinear periphery, like a home baked, spoonedcookie, with desirable surface cracks and crevices, and no pock marks orcraters caused by dragging or loss of particulates during dough pieceformation. The cookies may also have a large number of the inclusionswith substantial portions thereof extending above the surrounding bakeddough portions to provide a rich, indulgent appearance.

EXAMPLE 2

The ingredients and their relative amounts, which may be used to producea chocolate chunk cookie having high amounts of large chocolateinclusions and a home-baked appearance in accordance with the presentinvention are:

PARTS BY WEIGHT DOUGH INGREDIENT WEIGHT % GROUP 1 Butter 55.00 13.30Fine Grain Sugar, sucrose 40.00 9.67 Light Brown Sugar 2.00 0.48 Salt1.50 0.36 Cocoa 5.00 1.21 GROUP 2 Spray Dried Eggs 2.00 0.48 LiquidFructose 2.00 0.48 Water 17.19 4.15 Vanilla and Chocolate Flavor 5.001.21 GROUP 3 Wheat Flour 100.0 24.18 Sodium Bicarbonate 1.25 0.30Ammonium Bicarbonate 0.16 0.04 GROUP 4 Semi Sweet Chocolate Chunks 1,000count/lb 65.00 15.72 Medium White Chocolate Chunks 67.50 16.32 1,000count/lb Chocolate Chips 10,000 count/lb 50.00 12.10 TOTAL 413.60 100.0

The dough may be produced by first blending the Group 1 ingredients forabout four minutes at low speed. The Group 2 ingredients may then beadded to the Group 1 ingredients with mixing for about two minutes atlow speed, followed by addition of the Group 3 ingredients with mixingfor an additional four minutes at low speed, and the ammoniumbicarbonate being pre-dissolved in water. The Group 4 ingredients maythen be added and mixing may be continued for 1.5 minutes at low speedto obtain a substantially homogeneous dough.

The dough may be placed onto a lay-time conveyor for about 30 minutesfor hydration purposes. The dough may then be transferred to the hopperof a wirecut apparatus. The dough may then be ultrasonically cut as inExample 1, with a dough piece weight variation of less than about 10%,and then baked as in Example 1 to obtain cookies may have a curvilinearperiphery, like a home baked, spooned cookie, with desirable surfacecracks and crevices, and no pock marks or craters caused by dragging orloss of particulates during dough piece formation. The cookies may alsohave a large number of the inclusions with substantial portions thereofextending above the surrounding baked dough portions to provide a rich,indulgent appearance.

EXAMPLE 3

A chocolate chunk cookie may be produced as in Example 2 except the 1000count/lb medium white chocolate chunks may be replaced by an equalweight of random diced 600 count/lb white chocolate chunks.

1. A method for the continuous production of cookies having a highcontent of large inclusions comprising extruding a substantiallyhomogenous cookie dough having a high content of large inclusionsthrough a die aperture above a moving conveyor to provide a verticallyoriented dough rope, ultrasonically cutting the vertically orienteddough rope to obtain dough pieces having a roughened top surface whilecutting through inclusions so that the dough pieces fall onto saidmoving conveyor with said roughened top surface facing upward,transporting the dough pieces on said moving conveyor to an oven, andbaking said dough pieces into cookies having a cracked top surface andinclusions which extend above the baked cookie dough top surface.
 2. Amethod for the continuous production of cookies as claimed in claim 1wherein said ultrasonic cutting is performed with an ultrasonic cuttingblade which travels in a looped path to cut the dough rope at the dieaperture.
 3. A method for the continuous production of cookies asclaimed in claim 1 wherein the power supply to said ultrasonic cuttingblade is varied to produce surface roughness on the dough pieces.
 4. Amethod for the continuous production of cookies as claimed in claim 1wherein the amplitude of said ultrasonic cutting blade is varied as theblade cuts across the dough rope to provide a roughened top surface onthe dough piece.
 5. A method for the continuous production of cookies asclaimed in claim 1 wherein the cookie dough is extruded through aplurality of die apertures and a plurality of vertically oriented doughropes are cut by an ultrasonic cutting blade to obtain a plurality ofdough pieces having a roughened top surface, and said plurality of doughpieces fall onto said moving conveyor in an array of rows.
 6. A methodfor the continuous production of cookies as claimed in claim 1 whereinsaid die orifice has an irregular shape to provide dough pieces having acurvilinear perimeter so that upon baking the dough pieces are bakedinto cookies having a curvilinear periphery.
 7. A method for thecontinuous production of cookies as claimed in claim 1 wherein theinclusions comprise at least one member selected from the groupconsisting of confectionary chips, confectionary chunks, flavor chips,flavor chunks, dried fruit pieces, dried berries, and nuts.
 8. A methodfor the continuous production of cookies as claimed in claim 1 whereinthe dough weight variation from dough piece to dough piece is less thanabout 10% by weight, based upon the weight of the dough piece.
 9. Amethod for the continuous production of cookies as claimed in claim 2wherein said ultrasonic cutting blade travels in an elliptical path, andthe blade cuts across the dough rope first in an upward direction as theleading edge of the blade first encounters the dough rope, and then in adownward direction as the leading edge of the blade leaves the doughrope.
 10. A method for the continuous production of cookies as claimedin claim 9 wherein upon cutting the dough rope the top edge of the bladeis at a distance of less than about 20/1000 inches from the dieaperture.
 11. A method for the continuous production of cookies asclaimed in claim 1 wherein said cookie dough has an inclusion content offrom about 20% by weight to about 60% by weight, based upon the totalweight of the dough.
 12. A method for the continuous production ofcookies as claimed in claim 11 wherein said inclusions of said cookiedough have a particle size of from about 500 count/lb to about 1000count/lb.
 13. A method for the continuous production of cookies asclaimed in claim 12 wherein said inclusions comprise at least one ofchocolate chips, chocolate chunks, and nuts.
 14. A method for thecontinuous production of cookies having a high content of largeinclusions comprising: a) providing a cookie dough with an inclusioncontent of from about 20% by weight to about 60% by weight, based uponthe total weight of the dough, said inclusions having a particle size offrom about 500 count/lb to about 1000 count/lb, b) extruding the cookiedough through a die orifice to obtain an extrudate dough rope, c)cutting the extrudate dough rope with an ultrasonic cutting blade tosever the extrudate dough rope into dough pieces which fall onto amoving conveyer, wherein said severing provides a roughened top surfaceon a dough piece to provide a home baked appearance upon baking whilecutting through said inclusions without substantial displacement of theinclusions which would cause pock marks on the surface of the doughpiece.
 15. A method for the continuous production of cookies as claimedin claim 14 wherein the power supply to said ultrasonic cutting blade isvaried to produce surface roughness on the dough pieces.
 16. A methodfor the continuous production of cookies as claimed in claim 14 whereinthe amplitude of said ultrasonic cutting blade is varied as the bladecuts across the dough rope to provide a roughened top surface on thedough piece.
 17. A method for the continuous production of cookies asclaimed in claim 14 wherein the cookie dough is extruded through aplurality of die apertures and a plurality of dough ropes are cut by theultrasonic cutting blade to obtain a plurality of dough pieces having aroughened top surface, and said plurality of dough pieces fall onto saidmoving conveyor in an array of rows.
 18. A method for the continuousproduction of cookies as claimed in claim 14 wherein said die orificehas an irregular shape to provide dough pieces having a curvilinearperimeter so that upon baking the dough pieces are baked into cookieshaving a curvilinear periphery.
 19. A method for the continuousproduction of cookies as claimed in claim 14 wherein said ultrasoniccutting blade travels in an elliptical path, and the blade cuts acrossthe dough rope first in an upward direction as the leading edge of theblade first encounters the dough rope, and then in a downward directionas the leading edge of the blade leaves the dough rope, and wherein uponcutting the dough rope the top edge of the blade is at a distance ofless than about 20/1000 inches from the die aperture.
 20. A method forreducing dough weight variation in the continuous production of cookieshaving a high content of large inclusions comprising: a) providing acookie dough with an inclusion content of from about 20% by weight toabout 60% by weight, based upon the weight of the total weight of thedough, said inclusions having a particle size of from about 500 count/lbto about 1000 count/lb, b) extruding the cookie dough through a dieorifice to obtain an extrudate rope, c) cutting the extrudate rope withan ultrasonic cutting blade to sever the extrudate rope into doughpieces which fall onto a moving conveyer without substantial deformationof the dough pieces, and d) baking the dough pieces.
 21. A method forthe continuous production of cookies as claimed in claim 20 wherein thecookie dough is extruded through a plurality of die apertures and aplurality of dough ropes are cut by the ultrasonic cutting blade toobtain a plurality of dough pieces having a roughened top surface, andsaid plurality of dough pieces fall onto said moving conveyor in anarray of rows.
 22. A method for the continuous production of cookies asclaimed in claim 21 wherein said ultrasonic cutting blade travels in anelliptical path, and the blade cuts across the dough rope first in anupward direction as the leading edge of the blade first encounters thedough rope, and then in a downward direction as the leading edge of theblade leaves the dough rope, and the dough weight variation from doughpiece to dough piece is less than about 10% by weight, based upon theweight of the dough piece.
 23. A method for the continuous production ofcookies as claimed in claim 21 wherein the cutting of the dough ropeoccurs in the direction opposite to the direction of movement of theconveyor belt and cut dough pieces thereon.
 24. A method for thecontinuous production of cookies as claimed in claim 21 furthercomprising applying a curtain of air to the top surface of theultrasonic cutting blade for removing fines from the blade surface. 25.A method for the continuous production of cookies as claimed in claim 21wherein said cookie dough is a sticky or low fat cookie dough and theamplitude of blade motion is 12 microns to 18 microns.
 26. Apparatus forthe continuous production of cookies having a high content of largeinclusions comprising a wirecut machine having a plurality of dieorifices, a plurality of ultrasonic cutters which are each attached tothe wire cut machine and which each have an ultrasonic cutting blade,and a conveyor belt located below the wirecut machine, wherein theultrasonic cutting blades travel in a looped path and are synchronizedto cut across a plurality of die apertures which are above the movingconveyor to ultrasonically cut vertically oriented dough ropes extrudedfrom the plurality of die apertures to obtain dough pieces which fallonto the moving conveyor in a substantially uniform array of rows, eachof the ultrasonic cutters being configured to provide the ultrasoniccutting blades with an amplitude of blade motion which is 12 microns to18 microns.